U.S. patent application number 13/671867 was filed with the patent office on 2013-03-21 for method for producing a three-dimensional object from solidifiable material as well as an object produced therewith.
This patent application is currently assigned to ARBURG GMBH + CO. KG. The applicant listed for this patent is Arburg GmbH + Co. KG. Invention is credited to Eberhard DUFFNER, Herbert KRAIBUHLER.
Application Number | 20130071599 13/671867 |
Document ID | / |
Family ID | 46754374 |
Filed Date | 2013-03-21 |
United States Patent
Application |
20130071599 |
Kind Code |
A1 |
KRAIBUHLER; Herbert ; et
al. |
March 21, 2013 |
METHOD FOR PRODUCING A THREE-DIMENSIONAL OBJECT FROM SOLIDIFIABLE
MATERIAL AS WELL AS AN OBJECT PRODUCED THEREWITH
Abstract
A method serves to produce a three-dimensional object by
additive construction in direct construction sequence from
solidifiable material, which is either present in the starting
state in a fluid phase or can be liquefied, where multiple material
components are discharged alternately in a programmable manner by
means of multiple discharge units and configure different parts of
the object joined to one another as a result of the discharge,
where the geometric proportions obtained during discharge already
correspond to the object, and because the material components form
between them either edge regions merging into one another without
boundaries or boundary regions of the different material components
abutting one another without joining, a method and an object
produced therewith can be provided, in which boundary and edge
regions are formed "as if from one piece" between different
material components even in the case of complex geometries.
Inventors: |
KRAIBUHLER; Herbert;
(Lossburg, DE) ; DUFFNER; Eberhard; (Starzach,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Arburg GmbH + Co. KG; |
Lossburg |
|
DE |
|
|
Assignee: |
ARBURG GMBH + CO. KG
Lossburg
DE
|
Family ID: |
46754374 |
Appl. No.: |
13/671867 |
Filed: |
November 8, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/EP2012/003289 |
Aug 2, 2012 |
|
|
|
13671867 |
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Current U.S.
Class: |
428/57 ;
264/401 |
Current CPC
Class: |
B29C 64/112 20170801;
B29C 64/176 20170801; Y10T 428/19 20150115; B33Y 10/00
20141201 |
Class at
Publication: |
428/57 ;
264/401 |
International
Class: |
B29C 67/00 20060101
B29C067/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 4, 2011 |
DE |
10 2011 109 368.4 |
Claims
1. Method for producing a three-dimensional object in direct
construction sequence by additive construction from solidifiable
material, which is either present in the starting state in a fluid
phase or can be liquefied, wherein in the direct construction
sequence multiple material components are discharged alternately in
a programmable manner by means of multiple discharge units and,
already joined to one another as a result of the discharge,
configure different parts of the object, wherein the geometric
proportions obtained during discharge already correspond to the
object, wherein the material components between each other form
either edge regions merging into one another without boundaries or
boundary regions of the different material components abutting one
another without joining
2. Method according to claim 1, wherein the additive construction
occurs from layer to layer.
3. Method according to claim 1, wherein the solidifiable material
is discharged in the form of drops as the smallest discharge
quantity.
4. Method according to claim 3, wherein the drops join together in
a positive-locking manner.
5. Method according to claim 1, wherein the different material
components are placed next to one another drop by drop.
6. Method according to claim 5, wherein the drops join together in
a positive-locking manner.
7. Method according to claim 1, wherein there is discharged in the
edge region or boundary region a material component forming an
intermediate layer and configured as a separable connection between
the materials adjoining the intermediate layer.
8. Method according to claim 7, wherein a predetermined spacing or
a clearance between the parts of the object adjoining the
intermediate layer is set by means of the intermediate layer.
9. Method according to claim 8, wherein a material component is
discharged as a support for the at least one further material
component, which can be detached after production of the
object.
10. Method according to claim 1, wherein the material components
are not compatible with one another.
11. Object produced by a method according to claim 1, with multiple
adjoining parts, wherein after production the parts have a
structure connecting them composed of different material
components.
12. Object according to claim 11, wherein the structure connecting
the parts forms a sliding connection or an intermediate layer,
which adjoins the parts and is detachable upon movement.
13. Object according to claim 12, wherein the intermediate layer
forms a predetermined spacing or a clearance between the parts of
the object adjoining the intermediate layer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Patent
Application Number PCT/EP2012/003289 file don 2 Aug. 2012, which
designates the U.S. and which claims priority to German Patent
Application Number 10 2011 109 368.4 filed on 4 Aug. 2011, both of
which said applications are herein incorporated by reference in
their entirety.
TECHNICAL FIELD
[0002] The invention relates to a method for producing a
three-dimensional object from a solidifiable material and also to
an object produced therewith.
BRIEF DESCRIPTION OF RELATED ART
[0003] In plastic part production, parts are produced by injection
moulding or extrusion in large batch sizes and series using moulds.
The advantage of plastic injection moulding in particular rests
especially on the highly precise production of complex part
geometries, wherein the versatility of operation of the injection
moulding process covers the requirements for an inexpensive and
economical production of plastic parts in an optimum manner.
However, plastic injection moulding reaches its limitations when
materials that are not compatible with one another have to be
processed or, in the case of positive-locking connections in
particular, problems arise with removal from the mould.
[0004] At the same time, there is an ever-increasing demand for
plastic parts in a unit number of one and small batch sizes such as
pattern parts, for example, with the requirement of provision in a
very short period as well as properties that are similar to those
of injection moulded parts. For the production of such parts there
are production processes that are widely known by the term
prototyping and rapid manufacturing. The production of such parts,
in most cases, is based on generation of the geometry from 3D data
without tools, i.e. without moulds. These geometries are produced
in a wide variety of shapes by appropriate means such as melting
powder layers by the application of heat, e.g. by means of lasers,
additive systems such as compression processes in a different
connecting shape of the powder parts or also in the so-called melt
extrusion process. In particular, the powder processes also reach
their limitations when multiple different material components have
to be processed next to one another.
[0005] A device, wherein a plasticising unit known in injection
moulding technology is coupled to a pressurisable material storage
device for a liquid phase of a material, is known from EP 1 886 793
A1 that forms the basis of the preamble of claim 1. To generate an
object on an object support, this material is discharged in the
form of drops there through a discharge opening. Because of the
adhesion forces of the material a high pressure and high melting
temperatures are necessary for the material, especially as the drop
must have a size of 0.01 to 0.05 mm.sup.3 to obtain an appropriate
surface quality. Different parts of the object are already joined
to one another as a result of the discharging of the drops. The
geometric proportions obtained during discharge are substantially
retained during the production process and already correspond to
the object. It is already proposed there, paragraphs [0016] and
[0035], to discharge different material components by means of
multiple discharge units so that they mix with one another at the
impact point without separating. The aim in this case is a mixing
of material. Boundary regions of different materials or the use of
reactive multicomponents can thus be realised efficiently.
[0006] A laser sintering process, in which metal powder layers are
welded to one another by heat application by means of lasers, is
known from DE 692 06 357 T2. The supply of energy necessary for
this enables the object and its geometry to be formed only after
discharge of the material. The materials are welded or alloyed.
This influences the final external geometry of the object. In the
process a layered structure of a metal part is formed by
selectively assembling layers by welding and by applying by plasma
spraying virtually as a second component a very brittle auxiliary
layer for the assembly process that serves as support structure for
overhangs and also in order to minimise delays. After a layer is
applied, this is milled in order to have a defined geometry plane
for the next layer. In this welding process alloying materials can
be fused together so that the boundary layer comprises an alloy of
both materials.
BRIEF SUMMARY
[0007] Starting from this prior art, the invention provideS a
method and an object produced therewith, in which boundary and edge
regions are formed "as if from one piece" between different
material components even in the case of complex geometries.
[0008] This solution enables direct edge layer regions to be
generated with comparable firm connection with one another, as is
otherwise only possible with the use of one material component,
e.g. in the injection moulding process. Fusing edge layers, which
either merge into one another without boundaries and form a
connecting structure, but which are nevertheless not joined and can
form adjoining boundary regions or also intermediate layers, as
necessary, which can be activated later as a movable connection,
are formed in quick alternation in the transition regions between
different material components.
[0009] No combination of the plastic chains is formed in the
boundary layer even in the case of compatible materials. Instead, a
van der Waals electron bonding of the ends of the plastic chains of
the individual materials can occur. Moreover, no microscopic mixing
of the molecules occurs because of the relatively poor flowability
of the plastic molecules. Therefore, in the plastics technology
sense the boundary layer is not a compound but a boundary layer.
This applies all the more in the case of incompatible materials,
since this is then a matter of "point-microscopic positive-locking"
of the connection.
[0010] Where necessary, it is also possible to use a material
component so that it is configured as a support that can be
detached later after the production of the object. As a result,
overhangs can be generated on the object without any problem, while
at the same time corresponding surfaces of the finished object can
be produced by keeping to boundary regions or by the formation of
intermediate layers. This enables production down to a unit number
of one of objects that, on the one hand, have material properties
that are better than those of injection moulded parts, where
necessary, but on the other hand, also have such complex geometries
that they can be produced only with high expenditure with the
injection moulding process, if at all.
[0011] The use of appropriate intermediate layers, which are either
detachable upon movement of the adjoining parts and/or form a
sliding connection, also allows objects with complex geometries
with undercuts such as e.g. universal joints or ball joints to be
produced according to this method.
[0012] Further advantages are evident from the sub-claims and the
following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention is explained in more detail below on the basis
of exemplary embodiments represented in the Figures.
[0014] FIG. 1 shows an object produced from two material components
with an edge region joining the two material components in a
non-positive-locking manner;
[0015] FIG. 2 shows a further object produced according to the
method of the invention, on which a second material component is
moulded e.g. as a seal;
[0016] FIGS. 3a,3b show a ball and socket joint produced according
to the method directly after production and in the state of use
after after-treatment of an intermediate layer;
[0017] FIG. 4 shows a device for producing an object by means of
multiple material components.
DETAILED DESCRIPTION
[0018] The invention will now be explained in more detail in an
exemplary manner with reference to the attached drawings. However,
the exemplary embodiments are only examples that are not meant to
restrict the inventive concept to a specific arrangement. Before
the invention is described in detail, it should be noted that it is
not restricted to the respective structural parts of the device or
the respective method steps, since these structural parts and
methods can vary. The terms used here are merely intended to
describe particular embodiments and are not used for restriction.
Moreover, when the singular or indefinite article is used in the
description or in the claims, this also relates to the plural of
these elements unless the overall context clearly indicates
something different.
[0019] The Figures show different objects that are produced in
accordance with the method. The method serves to produce a
three-dimensional object such as rapid-prototype parts with the
multicomponent process, wherein the object is produced in direct
construction sequence using additive construction. In this case, an
additive construction is understood to be a gradual construction
generating the structural part, e.g. line by line or layer by layer
of an object. In an extreme case this relates to construction drop
by drop. In this case, "direct construction sequence" is understood
to mean that the object is constructed point by point, irrespective
of which material component must currently be output.
[0020] The solidifiable material, from which the three-dimensional
object 50, 50' or the ball and socket joint 60 according to FIGS.
3a, 3b as object is produced, is present either in the starting
state in a fluid phase or can be liquefied. The solidifiable
material is a plasticised material such as silicone, for example,
or a plasticisable material such as plastic or also materials in
powder form, wherein substantially what matters is that the
solidifiable material is present either in the starting state in a
fluid phase or can be liquefied. The material can also be a
material that is reversibly meltable under heat application and is
therefore recyclable. In principle, all materials such as resins,
thermoplastics, silicones and other support materials that allow an
additive construction are conceivable. Since a plasticising unit
known in injection moulding technology is preferably used for
processing the solidifiable material as plasticised or
plasticisable material, a standard commercially available material
or a material present during injection moulding can be used to
produce the parts. A special separate material is therefore not
necessary.
[0021] The discharge of the solidifiable material can occur either
sequentially in the form of drops from a discharge opening of at
least one timed or clocked discharge unit 12', as is known, for
example, from EP 1 886 793 A1. However, a discharge in strands from
a discharge unit can also occur, wherein combinations of both
discharge methods are possible for faster part formation. Multiple
discharge units, but at least multiple material storage devices,
are preferably provided that alternately discharge drops as the
smallest discharge quantity in a programmable manner. Different
parts of the object 50, 50' are thus already joined to one another
as a result of the discharge. Thus, the geometric proportions
already corresponding to the object 50, 50' are preferably already
formed during the discharge of the material in particular the
drops.
[0022] The discharge unit 12' according to FIG. 4 is actually known
from EP 1 886 793 A1 and is herewith incorporated by reference to
that specification. By discharging drops from the discharge unit
12' the object 50 is created layer by layer on an object support
13, which is movable on a construction table 113 in the three
spatial directions. A fibre element, which is embedded into the
solidifiable material at the point of impact, can be additionally
supplied, where required, by means of a fibre feed device
controlled by a fibre control device. The discharge unit 12'
connects to a material storage device 18, 18' for each material
component and material processed by a processing unit is fed under
pressure to the material storage device by means of a pressure
generating unit. By means of the preferably timed outlet the drops
are generated and transported in a construction area for
construction of the object 50, 50'. The discharge unit 12' is
preferably a part of a plasticising unit, which is actually known
in principle in injection moulding technology and which at the same
time also comprises the pressurisable material storage device for
incorporating the fluid phase. The pressure on the fluid phase in
the material storage device generates the drops by direct
coupling.
[0023] Multiple material components A, B or C, D are discharged by
means of multiple discharge units 12' and at least from multiple
material storage devices 18, 18'. The material components
respectively form parts of the object 50, 50' to be produced, as is
clearly shown in FIGS. 1, 2. Since the construction occurs in
direct construction sequence, in the case of multiple discharge
units a different material for the construction of the object can
be discharged in any desired sequence, i.e. layer for layer or line
for line and down to droplet by droplet. This discharge can change
in a programmable manner, i.e. depending on the program settings
and thus on the geometry of the object, different materials can be
placed alternately next to one another down to the smallest
discharge quantity of a drop and thus drop by drop. Thus, in FIG.
1, for example, edge regions 51 that virtually fuse together and
merge into one another without boundaries are formed between the
different material components A, B. This leads to a connecting
structure such as only results when using only one material or one
material component in a single process. Thus, in relation to the
drop size a kind of positive-locking connection such as e.g. an
interlocking connection occurs. However, it is also possible to
form boundary regions 52 between the different material components
that abut one another without joining. FIG. 2 shows the moulding of
a seal composed of a softer material component D, for example, onto
a further harder material component C, for example. Thus,
materials, which as a result of van der Waals forces or because of
reactive properties cannot otherwise be processed with one another,
i.e. are not compatible, can also be placed next to one
another.
[0024] The whole can be achieved, for example, by two discharge
units synchronised with one another discharging the material
components in any desired sequence. There can be an optimisation of
this process, for example, in the synchronous production of
multiple parts at a geometric spacing, in which the travel movement
paths of the discharge units are minimised. In principle, it is
recommended that the outlets of the two discharge units or the
material storage devices 18, 18' lie closely next to one another,
so that little time passes possibly for a travel movement during
the change of material components. Thus, fusing edge layers can be
formed in the edge region in very quick alternation.
[0025] A material component forming an intermediate layer 53 and
configured as a separable connection between the materials
adjoining the intermediate layer 53 can also be discharged in the
edge region 51 or boundary region 52. FIG. 3a shows a corresponding
configuration for the case of the production of a ball and socket
joint 60. The intermediate layer 53 is still recognisable in FIG.
3a, whereas in FIG. 3b it is replaced by a gap 54. As the structure
forming the parts of ball 61 and socket 62 the material of the
intermediate layer 53 can form a sliding connection and, as
required, can also be used as a sliding means in the ball and
socket joint. Thus, upon movement the intermediate layer 53 either
disintegrates completely or remains as sliding means. It can be
useful here to configure the boundary regions to abut one another
without joining in order to obtain a geometrically closed surface
of the parts that are later movable into one another. However, a
connecting structure can also be configured to hold the sliding
means in place. This shows what possibilities are made available to
a person skilled in the art completely as required with this
method. With this method a predetermined spacing or a clearance
between the parts of the object adjoining the intermediate layer 53
is settable by means of the intermediate layer, i.e. the spacing
can be changed in a programmable manner, where necessary, even from
part to part, which is only possible with extremely high
expenditure, for example, in the injection moulding process.
[0026] Therefore, in principle, an object, in which multiple
adjoining parts composed of different material components are
present, is produced with the method or can be produced therewith.
After the production the parts are joined to one another by a
structure composed of different material components connecting
them, wherein a structure results practically as in a production
from one material. However, the material component can also be used
so that it is discharged as a support for the further material
components that is detachable after production of the object. In
this case the boundary regions 52 are configured so that as good a
surface quality of the object as possible results "behind" the
support, wherein this geometry is already formed during discharge
of the material. Thus, overhangs can also be easily formed on the
object to be produced.
[0027] It is clearly understood that the material components do not
have to be compatible with one another and can still be placed next
to one another, as is possible, for example, with corresponding van
der Waals forces. Use is also possible, for example, with different
material properties such as in use of a material component that is
hard in the state of use, for example, and a soft material
component. In particular, the production of permanent connections
but also the production of toothing or other non-positive and
positive-locking connections are conceivable.
[0028] It is clearly understood that this description can be
subject to a wide variety of modifications, changes and
adaptations, which move into the realm of equivalents to the
attached claims.
* * * * *